Baldor BC140 Installation & Operation Manual
Baldor BC140 Installation & Operation Manual
BC140 DC CONTROL
MN703
TABLE OF CONTENTS
Section
Page
1 Introduction.............................................................................................................................................................................3
Safety Warnings and Cautions ...............................................................................................................................................6
2 Quick Start Instructions...........................................................................................................................................................9
3 Mounting Instructions ...........................................................................................................................................................12
4 Electrical Instructions............................................................................................................................................................12
5 Application Information .........................................................................................................................................................15
6 Setting the Voltage Select Switch .........................................................................................................................................16
7 Trimpot Adjustments.............................................................................................................................................................17
8 Operation..............................................................................................................................................................................20
9 Diagnostic LEDs and Pilot Light............................................................................................................................................20
10 Troubleshooting....................................................................................................................................................................21
11 Optional Auxiliary Heat Sink (Catalog No. BC143) ...............................................................................................................23
12 Optional Forward-Brake-Reverse Switch (Catalog No. BC144) ............................................................................................24
Baldor District Offices .................................................................................................................................................................25
Limited Warranty.......................................................................................................................................................... Back Cover
Tables
Page
1 Standard Features..................................................................................................................................................................3
2 Optional Accessories..............................................................................................................................................................4
3 Electrical Ratings....................................................................................................................................................................4
4 Trimpot Adjustments...............................................................................................................................................................4
5 General Performance Specifications ......................................................................................................................................5
6 Barrier Terminal Block Wire and Tightening Torque Specifications ......................................................................................13
7 Armature and AC Line Fuse Selection..................................................................................................................................13
8 Plug-In Horsepower Resistor and Armature Fuse Kit Information ......................................................................................14
9 Field Connection (Shunt Wound Motors Only)......................................................................................................................15
10 Troubleshooting Guide for Controls without Optional Forward-Brake-Reverse Switch Installed ...........................................21
11 Troubleshooting Guide for Controls with Optional Forward-Brake-Reverse Switch Installed ................................................22
Figures
Page
1 Cover Layout ..........................................................................................................................................................................5
2 Mechanical Specifications ......................................................................................................................................................6
3 AC Line, Armature, Field (Shunt Wound Motors Only), and Ground Connections ..................................................................9
4 Control Layout and Internal Connection Diagram .................................................................................................................11
5 Voltage Select Switch Setting...............................................................................................................................................16
6 Acceleration Trimpot (ACCEL) Range ..................................................................................................................................17
7 Deceleration Trimpot (DECEL) Range..................................................................................................................................17
8 Minimum Speed Trimpot (MIN) Range .................................................................................................................................17
9 Maximum Speed Trimpot (MAX) Range ...............................................................................................................................18
10 Current Limit Trimpot (CL) Range.........................................................................................................................................18
11 IR Compensation Trimpot (IR) Range...................................................................................................................................19
12 Optional Auxiliary Heat Sink Mechanical Specifications........................................................................................................23
13 Optional Forward-Brake-Reverse Switch Connections .........................................................................................................24
2
INTRODUCTION
Thank you for purchasing the BC140, full-wave variable speed DC motor control. Baldor is committed to providing total
customer satisfaction by producing quality products that are easy to install and operate. The BC140 offers the user the
ultimate in reliability and performance at an affordable price.
The BC140 represents the latest in state-of-the-art design, surface mount technology, incorporating advanced circuitry and
technology for variable speed DC motor controls. It is rugged and compact in size and is able to handle both 115 and
208/230 Volt AC line inputs by setting the built-in Dual Voltage Switch. In addition, one model can be used on a wide range
of motors by selecting and inserting the appropriate Plug-in Horsepower Resistor.
The standard model, BC140, controls all motors through 3/4 HP at 115 Volt AC line input and 1 HP at 230 Volt AC line
input. By installing the Auxiliary Heat Sink (see Table 2, on page 4), the horsepower range is increased to 1 HP at 115 Volt
AC line input and 2 HP at 230 Volt AC line input. The versatility of the control is enhanced with the optional
Forward-Brake-Reverse Switch Kit (Catalog No. BC144).
The electronics for the BC140 consist of a patented speed control module. Its field-proven reliability is confirmed by over
100,000 controls presently in operation. The module is housed in a rugged metal enclosure (not plastic, like less expensive
controls). Keyhole slots facilitate mounting and an easily accessible terminal block simplifies connections.
This product complies with all CE directives pertinent at the time of manufacture. Contact your local Baldor District
Office for Declaration of Conformity. Installation of a CE approved RFI filter is required (see Table 2, on page 4).
TABLE 1
STANDARD FEATURES
Feature
Description
Does not require programming. Uses adjustable trimpots which are
Simple to Operate
factory set for most applications.
AC Line Input Voltage (15%, 50/60 Hz)
115 and 208/230 Volts AC
Allows for selection of 115 Volt or 208/230 Volt AC line input.
Dual Voltage Selection (Under the Front Cover)
(Factory set to the "230" Volt position.)
Plug-In Horsepower Resistor (Supplied Separately)* Allows the control to be used on a wide range of motors.
Fusing*
Built-In AC Line Fuse. Armature Fuse (Supplied Separately).
MOV Protection
AC line input transient suppression.
Allow adjustment of Acceleration (ACCEL), Deceleration (DECEL),
Adjustable Trimpots
Minimum Speed (MIN), Maximum Speed (MAX), Current Limit (CL),
and IR Compensation (IR).
Diagnostic LEDs
Power On (PWR ON) and Current Limit (CL).
*Plug-In Horsepower Resistor and armature fuse must be properly selected to accurately calibrate the control.
Item
Auxiliary Heat Sink
Forward-Brake-Reverse Switch
RFI Filter
TABLE 2
OPTIONAL ACCESSORIES
Catalog No. Description
Extends the control's rating to 1 HP, at 115 Volts AC, and 2 HP, at 230
BC143
Volts AC. See Section 11, on page 23.
Includes Forward-Brake-Reverse Switch with dynamic brake resistor. See
BC144
Section 12, on page 24.
Panel mount. Rated 24 Amps at 115 and 208/230 Volts AC, single phase.
BC24-LF
Complies with CE Directive 89/336/EEC (EN55022 and/or EN55011)
relating to the EMC Class A Industrial Standard.
TABLE 3
ELECTRICAL RATINGS
Maximum Rating
Maximum Rating
without Auxiliary Heat Sink
with Auxiliary Heat Sink
AC Line Voltage
Motor
AC Line
DC
AC Line
DC
( 15%, 50/60 Hz)
Voltage
Current
Load Current Horsepower
Current
Load Current Horsepower
(Volts AC)
(Volts DC) (RMS Amps) (Avg. Amps) (HP, KW)) (RMS Amps) (Avg. Amps) (HP, (KW))
115
90 130
12.0
6.0
0.75, (0.6)
16.0
12.0
1, (.75)
230
180
12.0
6.0
1.5, (1.1)
16.0
12.0
2, (1.5)
Notes: 1. The BC140 can be converted to the higher rating by installing the Auxiliary Heat Sink (Catalog No. BC143).
2. The BC140 must be set for either 115 or 208/230 Volt AC line input by setting the Voltage Select Switch to the "115"
or "230" position, respectfully. When the control is set for "115", use only 90 130 Volt DC rated motors. When the
control is set for "230", use only 180 Volt DC rated motors.
3. Field voltage is 100 Volt DC with 115 Volt AC line input and 200 Volts DC with 230 Volt AC line input. Maximum
Field current is 1.0 Amps DC.
TABLE 4
TRIMPOT ADJUSTMENTS
Trimpot
Acceleration (ACCEL).
See Section 7.1, on page 17.
Deceleration (DECEL).
See Section 7.2, on page 17.
Minimum Speed (MIN).
See Section 7.3, on page 17.
Maximum Speed (MAX).
See Section 7.4, on page 18.
Current Limit (CL).
See Section 7.5, on page 18.
IR Compensation (IR).
See Section 7.6, on page 19.
4
Description
Sets the amount of time for the motor to accelerate from zero speed to full speed.
Sets the amount of time for the motor to decelerate from full speed to zero speed.
Sets the minimum speed of the motor.
Sets the maximum speed of the motor.
Sets the maximum amount of DC current that the motor can draw.
Sets the required voltage compensation to the motor to provide improved load regulation.
TABLE 5
GENERAL PERFORMANCE SPECIFICATIONS1
Factory
Description
Specification Setting
Speed Range (Ratio)
50:1
Armature Feedback Load Regulation (0 Full Load, 50:1 Speed Range) (% Base Speed))
12
2
Line Voltage Regulation (at Full Load, 10% Line Variation) (% Base Speed)
0.5
Operating Temperature Range with Optional Auxiliary Heat Sink (Catalog No. BC143) (C / F)
0 40 / 32 104
Notes: 1. CE Compliance requires BC24-LF RFI Filter. (See Optional Accessories, Table 2, on page 4).
2. Performance is for 90 Volt PM motors with 115 Volt AC line input and 180 Volt DC PM motors with 230 Volt AC line
input.
FIGURE 1
COVER LAYOUT
40
50
60
30
70
90
10
20
80
Allow
Motor
to Stop
Before
Reversing
REV
(%) SPEED
0
10
FWD
B
R
K
ON
OFF
FIGURE 2
MECHANICAL SPECIFICATIONS (INCHES [mm])
5.00
[127]
4.125
[105]
4X
4.00
[102]
0.39
[9.91]
5.63 7.00
[143] [178]
0.35
9.0
4X
0.2
[5.08]
Note: See Section 11, on page 23, for optional Auxiliary Heat Sink (Catalog No. BC143) Mechanical Specifications.
FIGURE 3
AC LINE, ARMATURE, FIELD*, AND GROUND CONNECTIONS
A-
A+
ARMATURE
F-
F+
FIELD
L1
L2
LINE
GND
*F- and F+ are Field connections for Shunt Wound Motors only.
2.2
Ground Connection: Connect all ground wires (earth), of connections to the control, to the green ground screw on
the chassis, as shown in Figure 3.
2.3
AC line Fusing: The control contains a built-in replaceable AC line fuse installed in the AC line fuse holder, as shown
in Figure 4, on page 11. Select the correct AC Line Fuse, as described in Table 7, on page 13.
Note: If fuse blows, check for wrong connections and shorted or grounded motor.
2.4
Armature Fusing: Select an armature fuse (supplied separately) and install in the armature fuse holder, as shown in
Figure 4, on page 11. Select the correct Armature Fuse as shown in Table 7, on page 13. (See note below.)
2.5
Plug-In Horsepower Resistor: Select the correct Plug-In Horsepower Resistor (supplied separately), according to
armature voltage and motor horsepower information in Table 7, on page 13. Install the correct Plug-In Horsepower
Resistor as shown in Figure 4, on page 11. (See note below.)
2.6
Permanent Magnet (PM) Motor Armature Connection: Connect the motor armature to Terminals "A+" and "A-" of
the Barrier Terminal Block, as shown in Figure 3, on page 9.
2.7
Motor Field (Shunt Wound Motors Only): Connect the motor field (of the shunt wound motor) to the Barrier Terminal
Block. For full voltage field, use Terminals F+ (positive) and F- (negative). For half voltage field, use Terminals F+
(positive) and L1 (negative). See Section 4.8, on page 15.
CAUTION! Do not connect motor armature leads to Terminals "F+" and "F-". Do not use Terminals "F+" and "F-" for
any purpose other than to power the field of a shunt wound motor. Shunt wound motors may be damaged if the field
remains energized without armature rotation for an extended period of time.
2.8
Voltage Select Switch: The Voltage Select Switch must be set as described in Section 6, on page 16. For 208/230
Volt AC line input, set the Voltage Select Switch to the "230" position (factory setting). For 115 Volt AC line input, set
the Voltage Select Switch to the "115" position.
2.9
Trimpot Settings: All trimpots have been factory set for most applications, as shown in Figure 4, on page 11. The
trimpots may be readjusted, as described in Section 7, on page 17.
2.10 Diagnostic LEDs and Pilot Light: After power has been applied to the control, observe the front panel indicator and
the board mounted LEDs, to verify proper control operation, as described in Section 9, on page 20.
2.11 Optional Auxiliary Heat Sink (BC143): Extends the horsepower rating of the control to 1 HP, with 115 Volts AC line
input, and 2 HP, with 230 volts AC line input. See Table 2, on page 4, and Section 11, on page 23.
2.12 Optional Forward-Brake-Reverse Switch (BC144): Used to dynamically brake the motor. It provides run/brake and
forward-brake-reverse operations. See Table 2, on page 4, and Section 12, on page 24.
Note: The Armature Fuse is supplied with the Plug-In Horsepower Resistor Kit. See Table 8, on page 14, for Catalog No.
and ratings.
10
FIGURE 4
CONTROL LAYOUT AND INTERNAL CONNECTION DIAGRAM
F-
A-
A+
ARMATURE
F-
F+
FIELD
L1
L2
LINE
GND
11
3 MOUNTING INSTRUCTIONS
The control is designed with a NEMA-1 / IP-40 enclosure for indoor use. It is recommended that the control be mounted
vertically on a flat surface with adequate ventilation. Leave enough room below the control to allow for AC line and motor
connections and any other connections that are required. A mounting template is included to facilitate mounting of the
control. See Figure 2, on page 6.
Care should be taken to avoid extreme hazardous locations where physical damage can occur. The control should be
located in an area where it will not be exposed to contaminants such as water, metal chips, solvents or excessive vibration.
Without the Auxiliary Heat Sink, the temperature around the control must not exceed 50 C (122 F). With the Auxiliary Heat
Sink, the temperature around the control must not exceed 40 C (104 F).
The control is designed with a removable cover. To remove the cover, the two screws must be removed. After mounting
the control and all connections are completed, install the cover and secure it with the two screws. Tighten the screws to
5 lbs-in (6 kg-cm). Do not overtighten.
4 ELECTRICAL INSTRUCTIONS
See Table 6, on page 13, for Barrier Terminal Block wire size and recommended tightening torque specifications.
WARNING! READ SAFETY WARNING AND CAUTIONS, ON PAGES 6 8, BEFORE USING THIS CONTROL.
DISCONNECT THE MAIN POWER BEFORE MAKING CONNECTIONS TO THE CONTROL.
WARNING! - TO AVOID ERRATIC OPERATION, DO NOT BUNDLE THE AC LINE AND MOTOR WIRES WITH
WIRES FROM SIGNAL FOLLOWING, START/STOP CONTACTS, OR ANY OTHER SIGNAL WIRES. ALSO, DO NOT
BUNDLE MOTOR WIRES FROM MULTIPLE CONTROLS IN THE SAME CONDUIT. USE SHIELDED CABLES ON ALL
SIGNAL CONNECTIONS OVER 12" (30 CM). THE SHIELD SHOULD BE EARTH GROUNDED ON THE CONTROL SIDE
ONLY. WIRE THE CONTROL IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE REQUIREMENTS AND
OTHER LOCAL CODES THAT MAY APPLY.
WARNING! DO NOT CONNECT SWITCHES OR RELAYS IN SERIES WITH ARMATURE OR CATASTROPHIC
FAILURE WILL RESULT.
CAUTION! The Voltage Select Switch position must match the AC line input voltage ("115" position for 115 Volt AC
line input and "230" position (factory setting) for 208/230 Volt AC line input).
CAUTION! If control is connected to a transformer, it is advisable to switch the secondary to disconnect power. If
the primary is switched, additional snubber capacitors may have to be added across the transformer ouput to
prevent damage to the power bridge.
12
Maximum
Motor Current
(Amps DC)
6
12
4.1
TABLE 6
BARRIER TERMINAL BLOCK WIRE AND TIGHTENING TORQUE SPECIFICATIONS
Recommended
Maximum Wire Size (Cu)
90 130 Volt DC
180 Volt DC
Tightening Torque
Motors
Motors
Maximum 50 Ft.
Maximum 100 Ft.
2
2
(Maximum HP)
(Maximum HP)
AWG
mm
AWG
mm
lb-in
kg-cm
1/2
1
16
1.3
14
2.1
12
13.8
1
2
14
2.1
12
3.3
12
13.8
AC Line Connection: Connect the AC line input to Terminals "L1" (Line Fuse) and "L2", as shown in Figure 3, on
page 9. If one of the AC line inputs is a neutral (N), connect it to Terminal "L2".
Note: This control operates on 115 or 208/230 Volt AC line input and is factory set for 208/230 Volt AC line input
(Voltage Select Switch is factory set to the "230" position). See Section 6, on page 16.
4.2
Ground Connection: Connect all ground wires (earth), of connections to the control, to the green ground screw on
the chassis, as shown in Figure 3, on page 9.
4.3
AC Line and Armature Fusing: The AC Line fuse is factory installed. The Armature fuse (supplied separately) must
be installed in the armature fuse holder, as shown in Figure 4, on page 11. Select the correct fuses, as shown in
Table 7. Fuses are available from your distributor. All fuses should be normal blow ceramic 3AG, MDA, or equivalent.
On domestic 230 Volt AC lines, separate branch circuit protection for each line must be used.
TABLE 7
ARMATURE AND AC LINE FUSE SELECTION
Approximate
Horsepower
Fuse Selection (Amps)
Motor Current
90 Volt DC
180 Volt DC
(Amps DC)
Motors
Motors
Armature
Line
1/100
1/50
0.2
0.5
12
1/50
1/25
0.3
0.5
12
1/30
1/15
0.33
0.5
12
1/20
1/10
0.5
0.75
12
1/15
1/8
0.8
1
12
1/12
1/6
0.85
1.25
12
1/8
1/4
1.3
2
12
1/6
1/3
2
2.5
12
1/4
1/2
2.5
4
12
1/3
3/4
3.3
5
12
1/2
1
5.0
8
12
3/4
1
7.5
12
12
1*
2*
10
15
25
*With optional Auxiliary Heat Sink (Catalog No. BC143).
13
4.4
AC Line Fuse: The AC Line Fuse acts as a disconnect in case of a catastrophic failure. If the AC Line Fuse blows,
the control is miswired, the motor is shorted or grounded, or the control is defective.
Note: Fuse each AC line conductor that is not at ground potential.
4.5
Armature Fuse: The Armature Fuse acts as a diagnostic indicator. If the Armature Fuse blows, it indicates that there
is a problem after the control's output. The Armature Fuse required can be calculated by multiplying the maximum DC
Motor Current times 1.7.
4.6
Plug-In Horsepower Resistor: A Plug-In Horsepower Resistor (supplied separately) must be installed to match
the control to the motor horsepower and voltage in order for the IR Compensation and Current Limit settings to be
correct. Select the proper Plug-In Horsepower Resistor according to Table 8. Selecting the proper Plug-In
Horsepower Resistor is as important as selecting the proper Armature Fuse.
Plug-In Horsepower Resistors are available from your distributor. Install the Plug-In Horsepower Resistor, as
shown in Figure 4, on page 11.
Note: Be sure the Plug-In Horsepower Resistor is inserted completely into the mating sockets.
TABLE 8
PLUG-IN HORSEPOWER RESISTOR AND ARMATURE FUSE KIT INFORMATION
Plug-In Horsepower Resistor and Armature Fuse Kit
Motor Horsepower
Plug-In
Horsepower
Approximate
Armature Fuse
Resistor
Rating
Value
Armature Voltage Armature Voltage Motor Current
(Amps DC)
(Amps)
Catalog No.
(Ohms)
90 130 Volts DC
180 Volts DC
1/100
1/50
0.2
1.0
0.5
BR1000
1/50
1/25
0.3
0.51
0.5
BR0510
1/30
1/15
0.33
0.35
0.5
BR0350
1/20
1/10
0.5
0.25
0.75
BR0250
1/15
1/8
0.8
0.25
1
BR0251
1/12
1/6
0.85
0.18
1.25
BR0180
1/8
1/4
1.3
0.1
2
BR0100
1/6
1/3
2
0.1
2.5
BR0101
1/4
1/2
2.5
0.05
4
BR0050
1/3
3/4
3.3
0.035
5
BR0035
1/2
1
5
0.025
8
BR0025
3/4
1
7.5
0.015
12
BR0015SP
1*
2*
10
0.01
15
BR0010SP
*With optional Auxiliary Heat Sink (Catalog No. BC143).
14
4.7
Permanent Magnet (PM) Motor Armature Connection: Connect the motor armature positive lead (+) to Terminal
"A+" and negative lead (-) to Terminal "A-", on the Barrier Terminal Board, as shown in Figure 4, on page 11. Be sure
the correct Plug-In Horsepower Resistor and Armature Fuse are installed, as described in Sections 4.5 and 4.6, on
page 14.
4.8
Terminal
Connections
F+, FF+, L1
F+, FF+, L1
5 APPLICATION INFORMATION
5.1 Motor Type: The BC140 is designed for permanent magnet (PM) and Shunt Wound DC motors. Controls operated
on 115 Volt AC line input are designed for 90 Volt SCR rated motors. Controls operated on 230 Volt AC line input are
designed for 180 and 90 Volt (step-down) SCR rated motors. Use of higher voltage motors will result in a reduction of
the available maximum speed. Also, if motor is not an SCR rated type, the actual AC line amperage of the control, at
full load, should not exceed the motors DC nameplate rating.
5.2
Torque Requirements: The motor selected for the application must be capable of supplying the necessary torque. In
order to ensure the motor is not overloaded, a DC ammeter should be connected in series with the armature. Be sure
the current under full load does not exceed the motor nameplate rating.
15
5.3
Acceleration Start: The BC140 contains an adjustable acceleration start feature which allows the motor to smoothly
accelerate from zero speed to full speed over a time period of 0.2 10 seconds. The acceleration trimpot (ACCEL) is
factory set for 2 seconds.
5.4
Limitation In Use: The BC140 controls are designed for use on machine applications.
WARNING - DO NOT SWITCH THE ARMATURE IN AND OUT OF CIRCUIT OR CATASTROPHIC
FAILURE WILL RESULT. IF ARMATURE SWITCHING IS REQUIRED, USE BC144 FORWARD-BRAKE-REVERSE
SWITCH KIT.
CAUTION! Contact your local Baldor District Office before using this control on constant horsepower
applications such as saws and drill presses. Do not use this control in an explosive atmosphere. Be sure the
BC140 is used within its ratings. Follow all instructions carefully.
For 208/230 Volt AC Line Input: Set the Voltage Select Switch to the "230" position (factory setting).
toggle should be in the lower position with "230" displayed at the top.
6.2
For 115 Volt AC Line Input: Set the Voltage Select Switch to the "115" position. The switch toggle should be in the
upper position with "115" displayed at the bottom.
FIGURE 5
VOLTAGE SELECT SWITCH SETTING
208/230 Volt AC Line Input
(Factory Setting)
115 Volt AC Line Input
16
The switch
7 TRIMPOT ADJUSTMENTS
The control contains trimpots which have been factory set for most applications. Figure 4, on page 11, illustrates the
location of the trimpots and their approximate factory set positions. Some applications may require readjustment of the
trimpots in order to set the control for a specific requirement. See Table 5, on page 5, for range and factory setting of all
trimpots. The trimpots may be readjusted as follows.
WARNING! IF POSSIBLE, DO NOT ADJUST TRIMPOTS WITH THE MAIN POWER APPLIED. IF
ADJUSTMENTS ARE MADE WITH THE MAIN POWER APPLIED, AN INSULATED ADJUSTMENT TOOL MUST BE
USED AND SAFETY GLASSES MUST BE WORN. HIGH VOLTAGE EXISTS IN THIS CONTROL. ELECTROCUTION
CAN RESULT IF CAUTION IS NOT EXERCISED. SAFETY WARNINGS AND CAUTIONS, ON PAGES 6 8, MUST BE
READ AND UNDERSTOOD BEFORE PROCEEDING.
7.1
FIGURE 6
ACCEL TRIMPOT RANGE
7.2
Deceleration Trimpot (DECEL): The DECEL Trimpot controls the amount of rampdown time when the Main Speed Potentiometer is adjusted to a lower speed. The
DECEL Trimpot is factory set to 2 seconds, which is the amount of time it will take for
the motor to decelerate from full speed to zero speed. To increase the deceleration
time, rotate the DECEL Trimpot clockwise. To decrease the deceleration time, rotate
the DECEL Trimpot counterclockwise. The DECEL Trimpot range is 0.2 10 seconds.
See Figure 7.
FIGURE 7
DECEL TRIMPOT RANGE
Note: If the DECEL Trimpot is set to greater than the natural coast time of the motor
and actual load, it will extend the deceleration time of the motor.
7.3
Minimum Speed Trimpot (MIN): The MIN Trimpot sets the minimum speed of the
motor when the Main Speed Potentiometer is set fully counterclockwise. The MIN
Trimpot is factory set to 0% of base motor speed. To increase the minimum speed,
rotate the MIN Trimpot clockwise. To decrease the minimum speed, rotate the MIN
Trimpot counterclockwise. The MIN Trimpot range is 0% 30% of base motor speed.
See Figure 8.
FIGURE 8
MIN TRIMPOT RANGE
Note: Readjusting the MIN Trimpot will affect the maximum speed setting. Therefore,
it is necessary to readjust the MAX Trimpot if readjusting the MIN Trimpot. It may be necessary to repeat these
adjustments until both the minimum and maximum speeds are set to the desired levels.
17
7.4
Maximum Speed Trimpot (MAX): The MAX Trimpot sets the maximum speed of the
motor when the Main Speed Potentiometer is set fully clockwise. The MAX Trimpot is
factory set to 100% of base motor speed. To increase the maximum speed, rotate the
MAX Trimpot clockwise. To decrease the maximum speed, rotate the MAX Trimpot
counterclockwise. The MAX Trimpot range is 50% 110% of base motor speed.
See Figure 9.
FIGURE 9
MAX TRIMPOT RANGE
Note: Do not adjust the maximum speed above the rated motor RPM or unstable
operation may occur. For moderate changes in the maximum speed, there will be a
slight effect on the minimum speed setting when the minimum is set to zero. There may be significant variation in the
minimum speed setting if the minimum speed is at a higher than zero setting.
7.5
Current Limit Trimpot (CL): The CL Trimpot is used to limit the maximum current
FIGURE 10
(torque) to the motor. The CL also protects the control from excessive current during
CL TRIMPOT RANGE
startup. The CL Trimpot is factory set to 150% of the full load current rating of the
motor. To increase the current limit, rotate the CL Trimpot clockwise (do not exceed
200% of the full load current rating of the motor (maximum clockwise position)). To
decrease the current limit, rotate the CL Trimpot counterclockwise. On cyclical loads,
it may be normal for the CL LED to momentarily flash. (Visible only if the cover is
removed.) The CL Trimpot range is 0% 200% of the full load current rating of the
motor. Some application may require a lower value so as not to damage process material or drive train components.
See Figure 10.
Note: In order for the Current Limit to operate properly, the correct Plug-In Horsepower Resistor must be installed for
the particular motor and input voltage being used, as described in Section 4.6, on page 14. Calibration of the CL
Trimpot is normally not required when the proper Plug-In Horsepower Resistor is installed.
To Recalibrate the CL Trimpot:
7.5.1 Disconnect the AC power and connect a DC ammeter in series with either motor armature lead. If only an AC
ammeter is available, connect it in series with either AC line input lead.
7.5.2 Set the Main Speed Potentiometer to approximately 30% 50% clockwise position.
7.5.3 Set the CL Trimpot fully counterclockwise. The CL LED will illuminate red.
7.5.4 Load the motor shaft in accordance with application requirements.
7.5.5 Apply power and rotate the CL Trimpot clockwise until the desired current reading is observed on the DC
ammeter. Factory Current Limit setting is 150% of the full load current rating of the motor. If using an AC
ammeter connected in the AC line input, the factory Current Limit setting will read 75% of the full load current
rating of the motor. Do not exceed 200% of the full load current rating of the motor (maximum clockwise
position).
WARNING! DO NOT LEAVE MOTOR SHAFT LOCKED FOR MORE THAN 2 3 SECONDS OR
MOTOR DAMAGE MAY RESULT.
18
7.6
19
8 OPERATION
WARNING! READ SAFETY WARNINGS AND CAUTIONS, ON PAGES 6 8, BEFORE OPERATING THIS
CONTROL OR SEVERE INJURY OR DEATH CAN RESULT.
8.1
With no AC power applied and the On/Off AC Line Switch set to the "OFF" position, remove the front cover by
unscrewing the two cover screws. See Figure 1, on page 5.
8.2
Set the Voltage Select Switch to the correct position, corresponding to the AC line input voltage. ("115" position for
115 Volt AC line input and "230" position (factory setting) for 208/230 Volt AC line input). See Figure 1, on page 5.
8.3
Install the correct Armature Fuse, as shown in Table 7, on page 13, and the correct Plug-In Horsepower Resistor as
shown in Table 8, on page 14.
8.4
Recheck all input AC line and motor connections. See Figure 3, on page 9.
8.5
8.6
Set the Forward-Brake-Reverse Switch (if installed) to the "FWD" or "REV" position.
8.7
Set the On/Off AC Line Switch to the "ON" position. Observe that the Pilot Light illuminates. Gradually increase the
Main Speed Potentiometer. The motor should smoothly come up to the desired speed and remain stable.
20
9.1
Power On (PWR ON) LED and Pilot Light: When the AC power is applied to the control and the On/Off AC Line
Switch is set "ON", the PWR ON LED, on the PC board, will illuminate green and the Pilot Light, on the front cover, will
illuminate orange.
9.2
Current Limit (CL) LED: The CL LED will illuminate red when the motor is overloaded, indicating that the current limit
set point has been reached (set by the CL Trimpot). See Section 7.5, on page 18.
10 TROUBLESHOOTING
Table 10 is a troubleshooting guide for controls without the optional Forward-Brake Reverse Switch installed. Table 11, on
page 22, is a troubleshooting guide for controls with the Forward-Brake-Reverse Switch installed. Both tables provide
information on symptoms, their possible causes, and suggested corrective actions.
WARNING! HIGH VOLTAGE IS PRESENT IN THIS CONTROL. DISCONNECT MAIN POWER BEFORE
MAKING CONNECTIONS TO THE CONTROL. THE COVER MUST BE PROPERLY SECURED, AFTER ALL SETUP
CONNECTIONS, AND ADJUSTMENTS ARE COMPLETE. THIS REDUCES ELECTRICAL SHOCK HAZARD. FAILURE
TO OBSERVE THIS WARNING COULD RESULT IN ELECTRICAL SHOCK OR ELECTROCUTION.
WARNING! HIGH VOLTAGE IS PRESENT IN THE CONTROL. IF POSSIBLE, DO NOT ADJUST TRIMPOTS
WITH THE MAIN POWER APPLIED. IF ADJUSTMENTS ARE MADE WITH THE MAIN POWER APPLIED, AN
INSULATED ADJUSTMENT TOOL (PROVIDED) MUST BE USED AND SAFETY GLASSES MUST BE WORN. FIRE
AND/OR ELECTROCUTION CAN RESULT IF CAUTION IS NOT EXERCISED.
TABLE 10
TROUBLESHOOTING GUIDE
FOR CONTROLS WITHOUT OPTIONAL FORWARD-BRAKE-REVERSE SWITCH INSTALLED
Symptom
Possible Cause
Suggested Corrective Action
On/Off AC Line Switch in "OFF" position. Set On/Off Switch to "ON" position.
Motor is not running and Pilot Light not
Replace Line Fuse. See Table 7, on
Blown Line fuse.
illuminated.
page 13.
Defective On/Off AC Line Switch,
Replace On/Off AC Line Switch.
Main Speed Potentiometer set fully Rotate Main Speed potentiometer
counterclockwise.
clockwise.
Check for defective motor, worn brushes,
Defective motor.
etc. Replace motor, if necessary.
Motor does not run and Pilot Light is Plug-In Horsepower Resistor not Install the correct Plug-In Horsepower
illuminated.
installed.
Resistor. See Table 8, on page 14.
Replace Armature Fuse. See Table 7,
Blown Armature Fuse.
on page 13.
Set CL Trimpot, as described in Section
CL Trimpot set fully counterclockwise.
7.5, on page 18.
Low AC line input voltage.
Check AC line input voltage.
Overload condition.
Reduce load.
Control in current limit mode (CL trimpot Increase setting of CL Trimpot, as
Motor hums, runs at very low speed, or
not set correctly), CL LED is illuminated. described in Section 7.5, on page 18.
slows down substantially when load is
Install the correct Plug-In Horsepower
applied.
Incorrect Plug-In Horsepower Resistor.
Resistor. See Table 8, on page 14.
Motor armature and field connections
Correct the connections.
interchanged (shunt motor only).
Table 10 continued on next page
21
TABLE 10 (CONTINUED)
TROUBLESHOOTING GUIDE
FOR CONTROLS WITHOUT OPTIONAL FORWARD-BRAKE-REVERSE SWITCH INSTALLED
Symptom
Possible Cause
Suggested Corrective Action
Overload condition.
Remove overload.
Install the correct Plug-In Horsepower
Incorrect Plug-In Horsepower Resistor.
Resistor. See Table 8, on page 14.
Readjust the CL and/or IR Trimpots, as
CL and/or IR Trimpots may be set
described in Sections 7.5 and 7.6, on
incorrectly.
Erratic motor performance.
pages 18 and 19.
Defective speed control module.
Replace speed control.
Recheck line voltage and the correct
Voltage Select Switch set to wrong
setting of the Voltage Select Switch, as
position.
described in Section 6, on page 16.
Defective motor, worn brushes, etc.
Repair or replace motor.
MIN speed trimpot set higher than 0% of Readjust the MIN Trimpot, as described
Motor continues to run with Main Speed base speed.
in Section 7.3, on page 17.
Potentiometer set fully counterclockwise.
Readjust the IR Trimpot, as described in
IR Comp trimpot set too high.
Section 7.6, on page 19.
Motor runs in wrong direction.
Motor armature leads are reversed.
Reconnect motor armature leads.
TABLE 11
TROUBLESHOOTING GUIDE
FOR CONTROLS WITH OPTIONAL FORWARD-BRAKE-RESISTOR SWITCH INSTALLED
Symptom
Possible Cause
Suggested Corrective Action
Faulty wiring or loose connections to the Correct the connections. See Figure 13,
Motor will not run in Forward or Reverse reversing switch.
on page 24.
direction.
Forward-Brake-Reverse
Switch
is Replace Forward-Brake-Reverse Switch
defective.
assembly.
Faulty connections or loose connections. Check and correct connections.
No braking action in brake mode.
Replace Forward-Brake-Reverse Switch
Defective Brake Resistor.
assembly.
22
5.63 7.00
[143] [178]
5.61
[142]
6.29
[160]
1.375
[34.9]
23
24
United States
MARYLAND
FLORIDA
Tampa, Puerto Rico,
Baltimore
Virgin Islands
6660 Santa Barbara Road
3906 East 11th Avenue
Suite 22-24
Tampa, FL 33605
Elkridge, MD 21075
Phone: 813-248-5078
Phone: 410-579-2135
Fax:
813-247-2984
Fax:
410-579-2677
GEORGIA
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Phone: 770-772-7000
Fax:
770-772-7200
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Phone: 508-854-0708
Fax:
508-854-0291
ILLINOIS
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Phone: 630-848-5100
Fax:
630-848-5110
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DETROIT
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Phone: 586-978-9800
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Phone: 616-785-1784
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IOWA
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Phone: 515-263-6929
Fax:
515-263-6515
MINNESOTA
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21080 134th Avenue North
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Phone: 763-428-3633
Fax:
763-428-4551
MISSOURI
St. Louis
422 Industrial Drive
Maryland Heights, MO 63043
Phone: 314-298-1800
FAX: 314-298-7660
KANSAS CITY
1501 Bedford Avenue
North Kansas City, MO 64116
Phone: 816-587-0272
Fax:
816-587-3735
NEW YORK
AUBURN
One Ellis Drive
Auburn, NY 13021
Phone: 315-255-3403
Fax:
315-253-9923
NORTH CAROLINA
GREENSBORO
1220 Rotherwood Road
Greensboro, NC 27406
P.O. Box 16500
Greensboro, NC 27416
Phone: 336-272-6104
Fax:
336-273-6628
OHIO
Cincinnati
2929 Crescentville Road
West Chester, OH 45069
Phone: 513-771-2600
Fax:
513-772-2219
CLEVELAND
8929 Freeway Drive
Macedonia, OH 44056
Phone: 330-468-4777
Fax:
330-468-4778
OKLAHOMA
TULSA
2 East Dawes
Bixby, OK 74008
Phone: 918-366-9320
Fax:
918-366-9338
continued on next page
25
INTERNATIONAL SALES
Fort Smith, AR
P.O. Box 2400
Fort Smith, AR 72902
Phone: 479-646-4711
Fax:
479-648-5895
CANADA
Edmonton, Alberta
4053-92 Street
Edmonton, Alberta T6E 6R8
Phone: 780-434-4900
Fax:
780-438-2600
Oakville, Ontario
2750 Coventry Road
Oakville, Ontario L6H 6R1
Phone: 905-829-3301
Fax:
905-829-3302
Montreal, Quebec
1844 William Street
Montreal, Quebec H3J 1R5
Phone: 514-933-2711
Fax:
514-933-8639
International Sales
Vancouver, British Columbia CENTRO AMRICA
Y CARIBE
1538 Kebet Way
Port Coquitlam, BC V3C 5M5 Residencial Pinares De Suiza
Pol. 15 #44,
Phone: 604-421-2822
NVA. San Salvador,
Fax:
604-421-3113
El Salvador
Winnipeg, Manitoba
Phone: +503 2288-1519
54 Princess Street
Fax:
+503 2288-1518
Winnipeg, Manitoba R3B 1K2
Phone: 204-942-5205
CHINA
Fax:
204-956-4251
Shanghai Jiahua
Business Center
AUSTRALIA
Room A-8421
Unit 3, 6 Stanton Road
808 Hong Qiao Road
Seven Hills, NSW 2147,
Shanghai 200030
Australia
Phone: 86-21-64473060
Phone: (61) (2) 9674 5455
Fax:
86-21-64078620
Fax:
(61) (2) 9674 2495
GERMANY
Unit 8, 5 Kelletts Road
Dieselstrasse 22
Rowville, Victoria, 3178
D-85551 Kirchheim
Australia
Munich, Germany
Phone: (61) (3) 9753 4355
Phone: +49 89 90 5080
Fax:
(61) (3) 9753 4366
Fax:
+49 89 90 8492
UTAH
Salt Lake City
2230 South Main Street
Salt Lake City, UT 84115
Phone: 801-832-0127
Fax:
801-832-8911
WISCONSIN
Milwaukee
2725 South 163rd Street
New Berlin, WI 53151
Phone: 262-784-5940
Fax:
262-784-1215
INDIA
14, Commerce Avenue
Mahaganesh Colony
Paud Road
Pune - 411 038
Maharashtra, India
Phone: 91 20 25 45 95 31
Fax:
91 20 25 45 95 30
ITALY
Baldor ASR AG
Succarsale Di Mendrisio
Via Borromini, 20A
CH-6850 Mendrisio
Switzerland
Phone: 0041 91 640 99 50
Fax:
0041 91 630 26 23
JAPAN
DIA Building 802,
2-21-1 Tsuruya-Cho,
Kanagawa-Ku
Yokohama, 221-0835, Japan
Phone: 81-45-412-4506
Fax:
81-45-412-4507
KOREA
Room 208-37
Incheon Industrial Goods
Circulating Center
Songhyeon 3-Dong, Dong-Gu
Incheon Korea, 401-705
Phone: 82 32 588 3253
Fax:
82 32 588 3254
MXICO
KM. 2.0 Boulevard Al
Aeropuerto
Leo 37545, Guanajuato,
Mxico
Phone: 52 477 761 2030
Fax:
52 477 761 2010
UNITED KINGDOM
6 Bristol Distribution Park
Hawkley Drive
Bristol BS32 0BF U.K.
Phone: +44 1454 85 9000
Fax:
+44 1454 85 9001
27
LIMITED WARRANTY
For a period of 2 years from the date of original purchase, Baldor will repair or replace without charge, controls which our
examination proves to be defective in material or workmanship. This warranty is valid if the unit has not been tampered with
by unauthorized persons, misused, abused, or improperly installed and has been used in accordance with the instructions
and/or ratings supplied. The warranty is in lieu of any other warranty or guarantee, expressed or implied. Baldor shall not be
held responsible for any expense, including installation and removal, inconvenience, or consequential damage, including injury
to any person, caused by items of our manufacture or sale. (Some states do not allow the exclusion or limitation of incidental
or consequential damages, so the above exclusion may not apply.) In any event, Baldors total liability, under all
circumstances, shall not exceed the full purchase price of the control. Claims for purchase price refunds, repairs, or
replacements must be referred to Baldor with all pertinent data as to the defect, the date purchased, the task performed by the
control, and the problem encountered. No liability is assumed for expendable items, such as fuses.
Goods may be returned only with written notification including a Baldor Return Authorization Number and any return
shipments must be prepaid.